Electric machines and drives, including various types of electric motors, play an ever-increasing role in the way of making Europe the first climate neutral continent in the world. In order to achieve a breakthrough in the field of energy efficient electric motors, novel approaches are needed: high performance sustainable materials and multi-material manufacturing technologies suitable for complex geometrics and capabilities to design and simulate structures and components based on those. The ambitious goal of MultiMag is to develop novel design tools, high performance materials and multi-material additive manufacturing (MM-AM) processes, hence, to manufacture ready assembled lightweight components for electric machines and leading to better performing machines, improved energy efficiency and shorter lead times. After use, the components can be dismantled, and the materials recycled effectively. MultiMag takes the full advantage of multi-material additive manufacturing. Stacked rotor and stator structures, combining dissimilar magnetic and electric insulating materials are developed, manufactured and validated to ensure mechanical, thermal, electrical and magnetic performance. Internal structures, enabling more efficient cooling, are studied and designed. Achieving ambitious objectives of MultiMag requires a holistic approach and innovations in all sectors, namely in design, materials, manufacturing, use and end-of-life. Each of these vital areas are addressed by MultiMag activities. We will develop a framework and specific toolbox for addressing complex design challenges, which are multi-material, multi-functional and multi-physics. Evaluation and development of matching material properties enabling to join dissimilar materials using AM processes is one of the key focuses of MultiMag. MultiMag approach requires also MM-AM processes to be developed further, as well as recycling of REEs.

MagNEO's objective is robust and sustainable REE-free permanent magnets (PM) for emergent energy & mobility applications. The concept hinges upon novel compositions of AlNiCo & HEAs undergoing similar spinodal decompositions, processed by additive manufacturing (AM). The recycling strategies developed will allow environmentally friendly repurposing of disparate metallic constituents, with emphasis on Co recovery. The targeted properties of the new PMs are (BH)max 60 kJ/m3 for Co 24% and (BH)max 72 kJ/m^3 for Co35%. MagNEO will be realised through the following strategies: 1) open-source modelling tools, machine learning guided high-throughput digital & experimental screening to accelerate the development of novel environmentally benign materials, with compositions suitable for AM, throughout multicomponent alloy phase spaces, 2) harness the competitive advantages conferred by AM, such as shape complexities and microstructure engineering, in tandem with comprehensive heat treatment. These will be crafting novel anisotropic microstructures characterized by higher coercivity, culminating in (BH)max values exceeding 60 kJ/m^3. The performance of the new PMs will be verified for a) low-speed PM generators in wind turbines & ship propulsion shafts, (b) high speed (>100 m/s) rotors in heat pumps and (c) ABS sensors & headlight systems in automotive. The upscaling process will be conducted through techno-economic analyses performed by the manufactures in synergy with the end-users. This procedure will begin with a proof of concept at TRL3-4 and will culminate with technology validation at TRL6. MagNEO stands out as a fusion between accomplished multidisciplinary experts who will contribute to training and joint actions with other European teams to increase the competitiveness and sustainability of European industry by bringing innovative materials and new methods closer to the market, while maintaining cost-effectiveness of REE-free products in consideration.